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Inductor element and method of manufacturing the same

a technology of a spherical element and a manufacturing method, which is applied in the direction of inductance, inductance with magnetic core, and inductance/yokes, etc., can solve the problems of insufficient pressure transmission, easy dc superposition, and low withstand voltage, and achieve excellent withstand, inductance and dc superposition characteristics.

Active Publication Date: 2018-07-19
TDK CORPARATION
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention aims to provide a method for making an inductor element that has good resistance to voltage, ability to induce current, and ability to handle DC current.

Problems solved by technology

In addition, since the shape of the small-hardness part collapses easily during the molding with re-pressing, a sufficient pressure transmission cannot be achieved, and the density of a part where the pressed powders are joined decreases particularly.
Furthermore, if a pressure during the re-pressing is high for increasing the density, a coil film is broken or an inner wall of a die and the surface of the magnetic powder are rubbed, and withstand voltage decreases easily.

Method used

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  • Inductor element and method of manufacturing the same
  • Inductor element and method of manufacturing the same
  • Inductor element and method of manufacturing the same

Examples

Experimental program
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first embodiment

[0040]As shown in FIG. 1, an inductor element 2 manufactured by a method according to an embodiment of the present invention includes a winding portion 4 and a core portion 6. In the winding portion 4, a conductor 5 is wound in a coil shape. The core portion 6 includes an inner circumferential portion (also referred to as an inner core portion) 6a positioned on an inner circumference side of the winding portion 4 and an outer circumferential portion 6b positioned on an outer circumference side of the winding portion 4. A magnetic powder and a resin constituting the core portion 6 are inserted into a space 6c between the conductor 5 constituting the winding portion 4 and the core portion 6.

[0041]In the inductor element 2 of the present embodiment, a top surface and a bottom surface of the core portion 6 are approximately perpendicular to the Z-axis, and a side surface of the core portion 6 is approximately perpendicular to a plane surface including the X-axis and the Y-axis. The wind...

second embodiment

[0060]Hereinafter, Second Embodiment is described using FIG. 4 to FIG. 6, but is not described with respect to common matters with First Embodiment (common components, effects, etc. / the same shall apply hereinafter).

[0061]As shown in FIG. 4, an inductor element 2A of Second Embodiment is different from the inductor element 2 of First Embodiment in position of the joint interface 7.

[0062]As shown in FIG. 5 and FIG. 6, examples of methods of manufacturing the inductor element 2A of Second Embodiment include a method of preparing a preliminary green compact 60a1 with a plate shape and a preliminary green compact 60b1 with a pot shape. A joint projected surface 70a1 of the preliminary green compact 60a1 with a plate shape and a joint projected surface 70b1 of the preliminary green compact 60b1 with a pot shape are joined, and the joint interface 7 shown in FIG. 4 is formed intermittently. In accordance with positional change of the joint interface 7, positions of lead portions 5a and 5b...

third embodiment

[0063]Hereinafter, Third Embodiment is described using FIG. 7 to FIG. 9, but is not described with respect to common matters with First and Second Embodiments (common components, effects, etc. / the same shall apply hereinafter).

[0064]In an inductor element 2B obtained by a method of manufacturing an inductor element of Third Embodiment, as shown in FIG. 7, there exist joint interfaces 7a1, 7a2, 7b1, 7b2, and 7c more than First Embodiment. Specifically, the joint interfaces 7a2 and 7b2 are formed intermittently between a central core portion 6a2 and an outer circumferential portion 6b2, and the joint interfaces 7a1, 7b1, and 7c are also formed intermittently at predetermined intervals in the Z-axis direction inside the outer circumferential portion 6b2. The larger the number of joint interfaces is, the better DC superposition characteristics tend to improve.

[0065]As shown in FIG. 8 and FIG. 9, examples of methods of manufacturing the inductor element 2B of Third Embodiment include a m...

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Abstract

A method of manufacturing an inductor element includes preparing an insert member including a winding portion where a conductor is wound in a coil shape. A plurality of preliminary green compacts is obtained by conducting a preliminary compression molding of a granule containing a magnetic powder and a resin at a pressure of 2.5×102 to 1×103 MPa. The insert member and the plurality of preliminary green compacts are integrated so that a joint interface of the plurality of preliminary green compacts is formed intermittently.

Description

BACKGROUND OF THE INVENTION1. Field of the Invention[0001]The present invention relates to an inductor element and a method of manufacturing the same.2. Description of the Related Art[0002]As an example of inductor elements, an inductor element where a coil is embedded in a core obtained by adding a resin to a metal magnetic powder and molding it with pressure is known.[0003]Patent Document 1 below discloses a method of manufacturing a coil device where a magnetic powder and a thermosetting resin are mixed and molded with pressure so as to form two pressed powders, and the pressed powders are re-pressed while sandwiching a coil portion and are thermosetted. When the pressed powders are molded with the re-pressing, there are provided with a large-hardness part where the shape of the pressed powders does not collapse and a small-hardness part where the shape of the pressed powders collapses, and the pressed powders are molded while the small-hardness part is being collapsed by the re-...

Claims

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Application Information

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IPC IPC(8): H01F27/255B29C43/18H01F27/02H01F41/04
CPCH01F27/255B29C43/18H01F27/02H01F41/04H01F2017/048H01F1/36H01F2017/046H01F17/04H01F41/00H01F41/0246H01F3/08H01F3/14H01F17/043B29K2995/0008B29K2505/00B29C43/14B29C2043/182B29K2101/10B29K2705/00H01L21/56
Inventor YAMASHITA, YASUHIDEYASUHARA, KATSUSHISATO, CHIOMI
Owner TDK CORPARATION